Duplicate sound record and process of making the same



HUBER/l QUAKE, 117E, F BROOKLYN, NEW YORK, ASSIGNOR OF QNE-HALIS" TU JACOB EHRLICH, OF NEW YQRK, N. Y.

DUIPLIGATE SOUND RECORD AND PROCESS 01E MING THE AllllE.

No Drawing.

- This invention relates to improved, duplicating sound records, tablets, disks or other bodies to be used in sound recording and sound reproducing machines, one objectof this invention being to produce records with sound Waves impressed thereon and therein, irrespective of the type or depth of the record grooves.

The application of this invention is not limited to any particular shape or size of article to be coated, but will be described as applied to producing a substantially permanent copy of the ordinary disk record for phonographs (or graphophones).

In its broad interpretations, my improved process may be described as employing a suitable foundation or base with a relatively thin layer or layers thereon, of record material having ingredients diifering from the characteristic elements of the base, which layers are united firmly and integrally to each other, and to said base.

More specifically, my improved process consists in placing upon a fibrous or nonfibrous, non-thermoplastic core or base, a. relatively thin layer or plurality of layers of a composition containing a thermoplastic combination of inorganic esters of cellulosic bodies as the nitrated celluloses. Between the substantially non-thermoplastic foundation and the cellulose ester coating composition or compositions, I may apply what may be termed a filler or sizing for the purpose of filling the pores or interstices of the base, one object of such application being to reduce the quantity of relatively expensive cellulose ester composition required to impart the result desired.

Sound records made by my improved process are superior in that the obtained impression is provided with a true cast surface, the material having no tendency to alter in composition, condition or form, and therefore retaining the record impression unimpaired in accuracy and tonal qualities for an indefinite period; and furthermore that the record may be made of less thickness and lighter Weight than has been customary heretotore, with perfectly solid and homogeneous walls, there being no observable tendency in the finished record to crack. flake, peel or warp, or to soften at normal summer temperatures.

Application filed February a, 1924. Serial No. 891,515.

By my process, I am able to produce a record which combines the desirable propproperty of thermoplasticity, softening at a temperature slightly above the temperature of boiling Water and' being sufliciently rigid at ordinary atmospheric temperature to render sound Waves impressed thereon, quite durable. But shellac is a natural product of uncertain and varying composition, and on this account is subject to extensive adulteration. It must be imported from long distances'and is prone to market manipulation.

In recent years the cost of shellac has risen to a point whereits continued use, is almost prohibitive, and forms a menace to the continued expansion of the phonograph record industry.

While many substitutes for shellac-have been brought forward, the majority of these are deficient in the desirable property of thermoplasticity,or are obtainable in insufficient commercial quantities and at a pro-- hibitive price.

Synthetic resins, as the phenol-aldehyde condensation products while admirably adapted for general molding purposes, when used as phonograph masses require too long a time in the impression molds to render their use in sound records useful on=account of materially diminished speed of production.

Solid composition records, from the relatively large amounts of barytes, and other fillers normally contained therein of high specific gravity, result in the formation of a record of considerable weight, necessitatinghigh transportation charges in marketing the product.

Heretotore it has been usual to place-the title of a phonograph record upon the same by a separate operation, or, less irequently by stamping the same upon the finished rec- 0rd; It is obvious, that the 0111 portion of the record which may be used or this purpose, is that relatively smaller central porsound 60 ords produced ,by my improved process,

may be. laced on the foundation by which ma be described as consisting of a light-weig t foundation, a sizing layer (if used) placed upon one or both sides of said foundation; an intermediate, highly thermoplastic cellulose ester layer superposed upon the foundation, or upon 'the sizing which has been placed upon the foundation, if sizing has been used; and a surface coating or coatings of cellulose ester of diminished thermoplasticity relative to the intermediate cellulose ester layer; said surface coating composition giving a hard, tough, durable exterior, admirably adapted to successfully withstand long continued usage.

As a base or foundation forphonograph record manufacture, I preferably em loy a compacted body of fibrous or non-fibrous material substantially non-thermoplastic, and which is suitable to receive thereon and therein, the composition or compositions about to be described, and satisfactory for e purposes intended. The foundation if of, or similar to, pasteboard, cardboard or laminated cellulose material, is preferably previously compacted and the major portion of the moisture and volatile matter contained therein, removed by evaporation at ordinary or elevated temperatures, and in any suitable manner. One or both sides of the foundation may have printed or illustrated thereon, in monochrome or polychrome, information of any kind orlcharacter, said printing, or illustrating, or both,

covering the entire or as much of the foundation surface as desired. This information printor p otographically, or otherwise. pon the foundation, for purposes of economy'or otherwise, I mayplace a suitable sizing composition for the purpose of filling the pores or interstices of the foundation, any sizing being suitable which will penetrate the foundation substance, dry at a moderately elevated temperature, and leave as a layer, a non-hygroscopic material upon which the supernatant layer or layers may anchor satisfactorily. As an example I have found casein preparations suitable for this purpose. The sizing may be applied in any suitable manner, mechanically or by hand, and the volatile portion contained therein allowed to evaporate spontaneously or with assistance, as by artificial heat. The sizing or filling composition must be transparent or A nearly so that there may be no. serious interference with the clearness or legibility of the printed or illustrated matter placed on the foundation, upon examination of the finished record.

The sizing should also be practically insoluble in the volatile solvents employed in the subsequent (intermediate and surface) coats, that is, the sizing (when used) should function as a protective or buffer layer, between the foundation and the intermediate and surface layer cellulose ester compositions.

My researches have demonstrated to me, that it is preferable ordinarily, to place upon the sized or filled foundation, first a composition in one or more coats relatively high in thermoplasticity, following this with a surface composition in one or more coats, which is relatively low in thermoplasticity and harder, tougher and more resistant to wear than is the intermediate cellulose ester layer. ,By manipulating the coatings or layers in this manner, I am able to obtain a high degree of thermoplasticity or moldability, coupled with great toughness and long wearing qualities, and at the same time produce an apparently unitary composition, -at least a composition, so far as observable, of entire homogeneity.

As an intermediate coating, I have obtained satisfactory results by employing a highly thermoplastic nitrated cellulose composition, dissolved in volatile and suitable solvents and solvent combinations now known, which solution of thermoplastic nitrated cellulose maybe applied to the foundation, or sized foundation in a single or plu- I rality of coats, being applied by brushing, by rolling, by a doctor blade, by immersion or otherwise, the volatile portion being allowed to evaporate in any suitable'manner, spontaneously or otherwise I do not confine myself to a particularly named nitrocellulose lasticizer, but to a nitrocellulose combination iiigh in thermoplasticity. The nature and amount of .plastifier employed will depend upon the solubility, viscosity and other physical characteristics of the nitrated cellulose employed, and the ratio of solvent to nonsolvent portion in the volatile solvent combination used to dissolve the thermoplastic nitrocellulose, as well known to those skilled in the art. Whether it is advisable to employ one or, more coatings in this intermediate layer, will depend upon the total solids (nitrated cellulose and plastifier) in the compositionused, and the depth of the individual coatings placed upon the base. Manipulation will al'sp be varied depending upon the amount and nature of the plasticizing body or bodies associated with the esterified cellulose, and the percentage of non-evaporable solids in the intermedlate coating composition. In general, however, the intermediate and surface coating compositions are adjusted, that the total thickness of the same will be measureably greater than the depth of the sound record undulations, so that, upon subjecting the coated foundation to the usual pressure and heat treatment process for sound record impression, the phonograph matrix will not appreciably cut into the foundation or foundation sizing, and a record of substantially maximum thermoplasticity, and maximum permanency and exterior toughness will result.

After the application of theintermediate coating, the record blank is preferably placed in a warm atmosphere for the volatile portion of the composition to, be removed, after which the relatively low thermoplastic nitrated cellulose solution is applied in a manner similar to. that of the intermediate coating composition. The number of coats of surface composition to be applied will be governed by the method of 'ap lication, the total solids presentin the sur ace composition, the viscosity of thenitrocellulose dissolved therein, and the nature, number, and relative proportion of solvents and non-solvents constituting the vol'atile portion of the surface coating composition. ll prefer to employ little or no plasticdnducing body or bodies in the surfacing composition, in order to obtain the maximum toughness and Wearing qualities, as has been set forth. The precise composition of the cellulose ester composition or solution will depend upon the avidity with which the solvents selected will dissolve the particular nitrated cellulose being used, and the proportion (for reasons of cheapness) of the non-solvent portion of the cellulose ester solution. As is Well known, the percentage composition in nitrogen of a nitrated cellulose is not a function of its solubility in a given solvent or solvent combination; neither can the nitrogen percentage in a nitrated cellulose be determined from its viscosity or conversely. The Howing qualitities of a pyroxylin are not devolatile portion is allowed to dissipate in any known manner until a dry, hard'layer is formed. So long as the transparency or translucency of the combined layers is not interfered with ,to the extent that the printing or illustrating "upon the foundation or base is not seriously impaired in le ibility,

.coloring matter, fillers, etc. may be a dad to an or all of the coats, as desired. While I have used small amounts of non-drying vegetable oils inthe various layers, such as.

castor oil, cottonseed oil, olive oil and the like, to impart softness and pliability; and while I have employed relatively small quantities of such materials as Canada balsam, Venice turpentine, other oils, lacquers and varnishes in conjunction with the cellulose ester composit-ions, in general, I prefer to obtain the plasticity and toughness 'by means of a plurality of layers of cellulose ester in conjunction with thermoplasticizers of the same, being applied to the foundation in such a manner that the maximum properties of moldability coupled with exterior toughness will result, as set forth herein. The total depth of coatings to be applied, will depend upon, and be governed by the nature of the matrix and the treatment to which the record is tobe subjected in impressing sound waves therein and thereon. And the number of coatings to be applied will depend upon the nature and composition of the individual coatings and their method of application, and the proportion of total solids to liquids present in the cellulose ester solution or solutions. 1

Having applied'as the intermediate portion, a highly thermoplastic cellulose ester in solution to obtain the thermoplasticity desired: and having applied as asurface layer a sufficient amount of relatively low nitrocellulose thermoplastic solution to obtain the surface toughness and wearing qualities of the film deposited; and having used'in the so doing solutions which upon evaporation to dryness do not seriously/impair the transparency or translucency of the combined coating compositions, and having removed from the coatings substantially all of the volatile solvent contained therein, the resultant article, comprising the treated or. sized foundationor base (if such base was sized) the intermediate coating of relatively high moldability, and the surface portion of relative lower thermoplasticity, comprises the 'completed record tablet, and is then ready to have impressed therein and thereon, by Ways now known, record grooves upon one or both sides. The time and temperature of pressure will be governed by the physical characteristics of the coated foundation, and forms no portionclaimed in this specification.

While I have exemplified my invention herein, by illustrating its application as applied to a foundation of cardboard, pasteboard or other cellulosic mass, I have obtained satisfactory results by using as a foundation, such materials as pressed wood pulp, paper, fabrics, chamois, tanned hides and skins, asbestos, etc. And while I have illustrated my invention herein by means of a specific example, it is to be understood that such' example may be departed from within wide limits and still conserve the essence and spirit of my invention.

Having now described my invention, and in what manner the same may be performed, what I claim and desire to secure by Letters Patent is:

1. A method of producing sound records which consists in print-ing u on a base of suitable material; treating said base with a filler or sizing composition; removing substantially the volatile portion from said sizing layer; applying to said sized base an intermediate layer of ahighly thermoplastic cellulose ester in solution in volatile solvents; substantially removing said volatile solvents from said intermediate layer; applying upon said intermediate layer as a surface coating a cellulose ester in solution of low thermoplasticity relative to the intermediate layer; removing substantially all the volatile solvent from said surface coating; and impressing thereon. and therein by heat and pressure the ridges of a record matrix; and 'cooling the same to form a pressed record sufliciently transparent or translucent that the aforesaid printing may be visible thereon, substantially as described.

2. A method of producing sound records which consists in printing upon a base of fibrous material; treating said base with a filler or sizing composition which is substantially insoluble in the solvents used in the succeeding compositions; removing substantially the volatile portion from said sizing layer; applying to said sized base an intermediate layer of a highly thermoplastic nitrated cellulose in solution in volatile solvents; substantially removing said volatile solvents from said intermediate layer; upon said intermediate layer as a surface coating, applyinga solution of nitrated cellulose of low thermoplasticity relative to the intermediate layer; removing substantially all the volatile solvent from said surface coating; impressing thereon and therein by heat and pressure the ridges of a record matrix; and cooling the same to produce a pressed record suiiiciently transparent or translucent to admit of the aforesaid printing being visible thereon, as herein set forth.

3. The herein described method of producing sound records which consists in coating cellulosic material with a sizing or filling composition; removing substantially all of the volatile portion of said size; apply ing to said sized base or foundation an intermediate coating of a cellulose nitrate made highly thermoplastic and dissolved in a volatile solvent mixture; substantially re-' moving the volatile portion from said highly thermoplastic nitrocellulose layer; applying upon said intermediate layer as a surface coating a nitrocellulose in solution in a volatile solvent combination; removing substantially the volatile solvent contained in said surface coating composition; impressing thereon and therein said coated base by heat 'neanvae and pressure the ridges of a record matrix; and cooling the same to form a pressed record, substantially as set forth.

4. A method for producing sound record which consists in printing upon a foundation of cellulosic material; coating said printed base with a plurality of coats of a nitrated cellulose in solution; removing the volatile portion of the nitrated cellulose solution after each layer of the same has been applied; impressing upon said printed nit-rocellulose coated foundation by heat and pressure, the ridges of a record matrix; and cooling the same to form a pressed record sufficiently transparent so that the aforesaid printing may be visible thereon, substantially as described.

5. A method of producing sound records which consists in coating structureless material containing printing thereon, with a sizing or filling of a non-nitrocellulosic character; removing substantially the volatile portion of said size; applying to said sized, printed base an intermediate-layer in one or more coats, of a highly thermoplastic nitrated cellulose dissolved in a volatile solvent combination; removing substantially all of the volatile portion; of said nitrated cellulose intermediate layer; applying upon said intermediate layer as a surface coating, one or more layers ofsolution of a nitrated cellulose relatively low in thermoplasticity in respect to the intermediate layer; removing the volatile portion of the solvent combination of the surface coating; impressing thereon and therein, by heat and pressure by ways now known, sound waves or indentations to form a pressed phonograph record;

said pressed record being sufiiciently transparent or translucent to admit of reading the printing aflixed to the base or foundation, substantially as herein described.

6. The herein describedmethod of producing sound records, which consists in printing or afiixing a graphical representation upon a cardboard-like foundation or base; treatingsaid ba:e with a sizing or filling composition the volatile portion of which is substantially a non-solvent of nit-rated cellulose in its plastic or non-plastic state; removing said volatile portion from said size; applying to said sized base in one or more coatings, a solution of a highly thermoplastic nitrated cellulose dissolved in a volatile solvent combination; removing substantially all of the volatile solvent portion of said highly thermoplastic nitrated cellulose solution; applying thereon a nitro' cellulose in solution of thermoplasticity relatively low as compared with the thermoplasticity of the nitrocellulose solution applied to the sized base; removing substantially all the solvent therefrom; impressing thereon by heat and pressure sound wave indentations to form a pressed phonograph record sufliciently transparent to admit of reading fibrous base of laminated material, may be or understanding the material affixed to the visible, substantially as described herein, base before sizing, substantially as set forth. 10. In a method of advertising, the print- 7 The herein method of producing sound ing upon a flexible base which is afterwards records which consists in aiiixi'ng printed .or covered with a plurality of coatings of va-.- illustrated matter to a foundation or base rying plasticity containing nitrated cellulose by ways now known; coating said base with in a transparent or translucent condition, the a sizing pr filling material in solution or. printed base with thermoplastic coating suspension; removing substantially all of thereon having sound Waves impressed therethe volatile portion of said size; applying in by ways now known, substantially as set to said sized base a highly thermoplastic forth herein.

nitrated cellulose composition in solution in 11. The herein described method of pro a volatile solvent combination, which'solvent ducing sound records for advertising puris substantially a non-solvent of the sizing poses, consisting in printing or otherwise material; removing substantially the volatransferring the advertising matter onto a tile solvent from the highly plastic nitrated flexible base, preventing the defacement of cellulose; applying upon said nitrocellulose said printing and adding to its permanency layer as a surface coating, a nitrocellulose by coating said flexible base in the shape of a in solution of viscosity relatively low as disk, with a plurality of substantially transcompared with the intermediate layer of parentcoats of thermoplastic nitrated cellu nitrated cellulose; removing substantially lose of varying plasticity in solution in a all of the volatile solvent from the aforesaid volatile solvent combination; removing the nitrated cellulose surface coating; and imvolatile portion of the nitrated cellulose pressing thereon and therein sound wave insolution; impressing upon and in said coatdentations by ways now known; cooling ing material by means of heat and pressure, said pressed record mass, to .form a mersound wave undulations to form a phonochantable record sulliciently transparent to graph record with reading matter thereon, admit of seeing the imprint afixedto the substantially as described. base, substantially as set forth herein. 12. The method of producing sound rec- 8. The herein described sound record ords which consists in impressing a graphical tablet, comprising aywaterproofed foundarepresentation upon a foiindation of cellution which has printing upon its surface; losic com osition, applying an intermediate a plurality of coats of nitrocellulose solution coating 0 highlythermoplastic material to in volatile solvents; said waterproofing and said foundation, subsequently applying a nitrated cellulose coatings being sufficiently second layer of material possessed of low a transparent so that the printing affixed to thermoplasticity over the first layer, and imsaid vvaterproofed foundation is visible after pressing thereon the ridges of a record ma the coated foundation has been impressed trix. with sound wave indentations, substantially 13. The method of producing sound recas set forth. ords consisting in coating a cellulosic ma- 9. The herein described method of proterial with sizing, applying an intermediate ducing a light-weight, flexible, durable sound coating of highly thermoplastic material, aprecord, which consists in printing upon a plying on said intermediate layer a surface fibrous base of laminated material; partially coating of a material of low thermoplasticity waterproofing said base by the application and impressing thereon the ridges of a rec thereon and thereto of a sizing composition 0rd matrix. I immiscible with the subsequent coating com- 14:. A method for producing sound records positions; removal of substantially all of the which consists in impressing a graphical repvolatile portion of said sizing composition resentation on a base, coating said im ressed after applying thesame to the printed base; base with an intermediate coating 0 mateapplying to said sized base as an intermedirial of high thermoplasticity, appl t; a ate coating, a solution of highly thermosurface coating of material havlng a ow plastic nitrated cellulose in a volatile solthermoplasticity and impressing thereon the vent combination; removing the volatile porridges of a record matrix. tion-of the nitrated cellulose solution by 15. The method of producing sound recevaporation ;v applying to said intermediate ords which consists in impressing a graphinitrocellulose layer, a surface coating of cal representation upon a foundation of col- 'nitrocellulose of plasticity relative low as lulosic material, coating the imprinted base compared with the plasticity of the interwith a plurality of coats of nitro-cellulose in mediate composition; removing the volatile solution, removing the volatile portions of portion from said nitrocellulose surface coatsaid solution after each layer of the same ing; impressing by heat and pressure sound has been a plied and impresslng the rldges waves upon the said surface coating, to form on a recor matrix thereby to form a record.

a phonograph record sufficiently transpar- 16. The method of producing sound rec- 18o ent so that the printing aflixed upon the ords which consists'in coatinga base witha Hit ' plurality of layers of nitro-cellulose in solution, the first of which layers is of high thermoplasticity and the second of which is of low thermoplasticity and impressing the ridges of the record matrix, thereon.

17 The method for producing sound records consisting in coating a base With a plurality of coats of nitro-cellulose solution, removing the volatile portion of the cellulose solution after each layer of the same has been applied, and impressing the ridges of a record matrix thereon.

18. The method of producing sound records consisting in impressing a graphical eanne representation upon a foundation of cellu- M losic material, applying to said foundation an intermediate coat of highly thermoplastic nitro-cellulose composition, applying upon said intermediate layer as a surface coating a Intro-cellulose composition of 20 lower thermoplastioity and impressing on said coated base the ridges of a record matrix.

In testimony whereof l have signed my name to this specification this 6th day of 2 February, 1924.

ROBERT QUAKE, JR. 

